Method and apparatus for packaging flexible containers

ABSTRACT

An apparatus for packaging flexible-pouch packaged goods into cartons, trays, or the like is disclosed. An infeed section receives the packages from a source, orients the packages, and presents them to a picking device. The picking device has at least one picker head which contains a plurality of grabbers. The grabbers clutch the pouches, translate them to the tray or box loading station, then deposit the pouches in a composite motion which enables the pouches to be laid down in a space efficient and visually pleasing shingled manner. The process is controlled by a control unit programmable for a variety of product packaging configurations. The apparatus and process are especially suited for use with stand-up type or gussetted pouches.

FIELD OF THE INVENTION

[0001] The present invention relates to the field of container packagingmachines, and more particularly to a cartoner for placing objects withina carton or tray in a preselected orientation.

BACKGROUND OF THE INVENTION

[0002] It is well known to place uniform objects in cartons forshipping, sales, storage, organization, or display. The consumer productindustry has made many different product configurations available, andit is an ongoing pursuit of the packaging industry to find the leastexpensive, highest speed, and highest quality method of packaging theproducts into containers containing multiple products.

[0003] Some of the more challenging types of products to package orthose in non-rigid containers, e.g. pouches or packets which are formedfrom a flexible material. Many of these types of pouches are known, e.g.those disclosed in U.S. Pat. No. 6,164,825; D434,976; U.S. Pat. No.6,116,782; D420,900; D410,838; and U.S. Pat. No. 5,860,743, thedisclosures of which are incorporated as if fully set forth herein. Theyare suitable for various consumer products, e.g. liquid, gel,particulate, shredded, sliced, or solid materials.

[0004] However, handling these products in large quantity in ahigh-speed manner can be challenging. Heretofore, vacuum picker systemshave been used for handling these pouches, as their lack of uniformshape and orientation (due to their inherent flexibility and shifting ofthe product therein) can give difficulty to mechanical handling systems.However, for vacuum systems to work effectively, the packages must beessentially perpendicular to the vacuum picker. In real life terms, thismeans the packages must be spread out on a conveyor belt, which slowsdown the packaging speed and adds cost.

[0005] Various mechanical systems for handling pouches or other packagesare known, e.g. those disclosed in U.S. Pat. Nos. 6,170,225 B1;6,168,004 B1; 6,164,041; 6,151,867; 6,122,898; 6,092,979; 5,938,011;5,855,105; 5,333,721; and 3,996,723.

[0006] Mechanical picking devices, e.g. those manufactured by GoodmanPackaging Equipment, which pick up packages and can be programmed to laythem down in preselected configurations, are also known.

[0007] However, none of these yield a high speed high quality method ofhandling flexible pouches and the like in a process of cartooning orplacing in trays according to the present invention.

OBJECTS OF THE INVENTION

[0008] Thus, it is an object of the present invention to provide ahigh-speed pick-type packer which picks pouches and places them in acarton in a preselected orientation.

[0009] It is another object of the present invention to provide acompact cartoner/trayer with the ability to handle a large number offlexible packages of slightly different dimensions at a high speed.

[0010] It is yet a further object of the present invention to provide asystem for orienting flexible packages in a “shingled” manner in acarton or tray in a space and time-efficient manner.

[0011] It is an additional object of the present invention to provide asystem, which allows for the simultaneous placement of two differentlyoriented rows of “shingled” flexible pouches.

[0012] It is a further additional object of the present invention toprovide a mechanical picking system with a gentle touch to preventdamage to the flexible pouches yet handle them securely.

[0013] It is yet an additional object of the present invention toprovide a secure and flexible arrangement of equipment for handlingso-called “stand-up” or “gussetted” pouches.

[0014] These and other objects of the instant invention will becomereadily apparent to those of skill in the art having regard for theinstant disclosure.

BRIEF DESCRIPTION OF THE INVENTION

[0015] To accomplish the above objects and to solve the above handlingproblems, the applicants have devised a novel picking system whichsecurely handles flexible pouches, such as juice containers, bottledwater containers, and the like. The pouches are manufactured and filledby any of a number of processes, including those disclosed in U.S. Pat.No. 6,041,970, which is incorporated by reference as if fully set forthherein. However, they usually emerge from the manufacturing line indisarray, or placed in stacks in a box. Given their nonuniform shape(e.g. thin on the top and larger on the bottom, in the case of stand upjuice or drink containers such as those disclosed in U.S. Pat. No.6,164,825) much space is wasted in the initial containers off theproduction line.

[0016] Furthermore, consumers and retailers alike prefer to save shelfspace and enjoy a product that is arranged in a manner which they findvisually appealing.

[0017] Thus, the present invention contemplates supplying a method andapparatus for packaging nonidentical flexible packages in trays or boxesin a manner which is efficient and novel.

[0018] The present invention is especially suited for handling gussettedpouches which are capable of standing on their bottom portions. Thesepouches are also known in the industry as Doyen or simply “Doy” packs.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a side plan view of the first stage of an apparatusaccording to the present invention including an infeed and orientationdevice.

[0020]FIG. 2 is a top view of a split-belt conveyor which canindependently move groups of packages.

[0021]FIG. 3 is a side plan view of a conveyor-picker apparatusaccording to the present invention.

[0022]FIG. 4 is a side plan view of an individual picker unit accordingto the present invention.

[0023]FIG. 5 is a side view of the translation apparatus according tothe present invention.

[0024]FIG. 6 is a view in partial perspective of the boxing step of themethod of the present invention.

[0025]FIG. 7 is a side view of a multiple layer shingled box packagedaccording to the present invention.

DETAILED DESCRIPTION

[0026] As this invention may be more easily explained by reference tothe attached drawings, it should be noted that the figures arerepresentative and exemplary of the invention only, and should not beconstrued as limiting the scope of the invention in any way.

[0027] The invention is suitable for wide-ranging types of products,including commonly known liquid pouches as disclosed above, pouches forchewing tobacco, shredded cheese, dry or liquid baby formula,freeze-dried concentrates, condensed milk, pharmaceutical preparations,ointments, lotions, etc. Beverage pouches, containing carbonated andnoncarbonated beverages, are especially preferred for use in the presentinvention.

[0028] The pouches (or bags, flexible containers, etc.) which arehandled by the apparatus and method of the instant invention preferablyare reasonably uniform in size and shape, although substantial productshifting may in fact alter the absolute dimensions of the packagingsomewhat. The pouches need have at least one edge which may be graspedby a movable opposing pair of fingers. It is preferred, but notnecessary, that the pouches are somewhat flattened in shape, such thatthey may lay down on one side.

[0029] Especially preferred are stand-up type pouches, gussettedpouches, or the commonly known “Doyen” or “Doy” pack.

[0030] For example, a pouch made of two similarly sized sheets athermoplastic material which has been heat welded together will tend tobe a flattened pouch with a top and bottom, and edges which may begrasped. Such pouched may by stacked, shingled, etc. by the apparatusaccording to the present invention.

[0031] The material of the pouch can be any of a variety of materials.One such suitable material is a laminated thermoplastic material, suchas an outer layer of polyethylene terephthalate (Mylar®) and an innerlayer of low-density polyethylene. Such an arrangement is disclosed inU.S. Pat. Nos. 3,763,622 and 3,893,834 for hot and cold packs. Alsoknown are microwavable hot and cold packs from Francis, Jr., U.S. Pat.No. 4,920,964, which disclose a completely sealed envelope constructedfrom opposed laminate layers. U.S. Pat. No. 6,116,782, to Kraft Foods,Inc. discloses a multiplayer laminate wall including a polyester film,printing ink, adhesive, foil, adhesive, and polyethylene film for bagshaped beverage containers.

[0032] A well known container, e.g. that known for Capri Sun® beveragepouches available from Kraft Foods, Inc, a unit of Philip MorrisCompanies, Inc., which uses polyethylene terephthalate as the polyesterfilm and aluminum as the metal foil, is disclosed in U.S. Pat. No.5,425,583, and is particularly suitable for the practice of the presentinvention.

[0033] In brief overview, an apparatus according to the presentinvention takes a pouch, e.g. a stand up; gussetted, Doyen or “Doy”pack, and grips a side between the bottom and top. The pack or pouch islifted, moved laterally, lowered, and placed into a box. In preferredembodiments, a plurality of pouches are simultaneously picked up, moved,lowered, and placed into a box. In a particularly preferred embodiment,the lifted pouches are moved relative to the box into which they arebeing placed.

[0034] Turning now more specifically to FIG. 1, a powered infeedconveyor 100 is supplied with a supply of flexible pouches 102 (e.g.gussetted, stand-up, Doyen, or Doy) from a manufacturing plant (notshown). The manufacturing plant may take various liquid, gelatinous, orsolid (e.g. usually finely divided granular or particulate) materialsand place them within a sealed pouch as discussed above. Suitableconsumer products may include concentrates for liquid refreshments,nuts, candy, chewing tobacco, individually wrapped hard candies, and thelike.

[0035] Such suitable packs are conveyed along the infeed conveyor 100 bymeans of a powered driving wheel 104 which is connected to a controlunit 106. The control unit controls the speed and duration of the motionof the first conveyor. When the packages reach the end of the poweredfirst conveyor 100, they are conveyed by gravity and momentum torecipient second conveyor 108, which is provided with receiving guides110 which delimit a compartment for the packaged product. In essence,the packages 102 are thrown to the receiving conveyor 108.

[0036] The passage of packages 102 to the receiving conveyor 108 isrecorded by detector 112 which can count the number of packages andtransmit this information to the control unit 114. This information maybe used then to tally the total number of packages processed, and laterdownstream control as discussed below.

[0037] Detector 112 is connected to controller 114 which is preferably acomputing device configured with appropriate software, firmware, and/orhardware applicable to the task at hand. The controller has a databasefor recording input information such as number of units processed,faults, etc., and is capable of receiving instructions relating to howfar and how fast to move the apparatus as it goes through its variouspackaging motions.

[0038] For example, packages and shipping containers into which thepackages are to be inserted can vary dramatically from consumer productto consumer product, therefore, the machinery and apparatus according tothe present invention is adjustable to accommodate such variances.

[0039] Controller 114 advances the secondary recipient belt in responseto its preprogrammed instructions and input from the detector. The beltis physically driven by motor or powered wheel 116. As the passage ofeach package or flexible pouch is recorded, the belt is advanced in timeto receive the next pouch.

[0040] The pouches are preferably gathered together in groups, whichwill reflect a unit layer or packaging of the finally packaged productsin the container. In FIG. 1, six pouches are seen in each “flight” whichwill be inserted or placed on a surface for wrapping, into a tray orother carton-like container, or stacked.

[0041] As may be seen from FIG. 1, the pouches are physically orientedwith an edge facing upwardly and available to be grabbed.

[0042] Turning now to FIG. 2, a particularly suitable belt arrangementis seen for conveying the “flights” of product separately. It includes aplurality of parallel belts, inner belt 200 and outer belts 202.Attached to inner belt 200 are guides 204 which are affixed to theflexible belt. Inner belt 200 can be driven separately from outer belts202, thus enabling a flight of product to be relocated independent ofthe ongoing loading operation of another flight. This significantlyreduces the orientation time required to get the product into place forthe later picking operation.

[0043] The outer belts have receiving guides 206 attached thereto. Theouter belts are driven preferably synchronously to keep the productstraight, unless crooked loading of product is desires, in which case anasynchronous drive and pivotable mountings might be used.

[0044] Turning now to FIG. 3, the picking device 300 according to thepresent invention is seen. It has multiple picking units 302 which eachhave a plurality of individual picking heads 304, which in turn have apair of opposing picking fingers 306. The picking fingers are openableand closable, preferably by pneumatic actuation, for ease and speed ofuse and maintenance. Pneumatic equipment can be lighter and move quicklywith enhanced reliability. Although less preferred, electromechanicallydriven grabbers may also be used.

[0045] The individual picking heads can be individually programmable,such that only the correct number and sequence of heads opens and closesabout the edge 308 of the product 310 within grasping distance.

[0046] In use, the loaded flights of product are moved to picker loadingzone PLZ by the controller 313. It is now apparent how the multipleparallel belts which can individually move product are very useful andtime efficient. Even while the picker loading zone is being readied forthe picking action, yet more product is being loaded on a third flight312.

[0047] The picking units 302 then descend to within range of the productvia actuator set 316; again controlled by the controller 314. Thepicking fingers 306 are then closed about the edge of the product bycommand from the controller. The picking units 302 are then raised upvertically enough to clear the product from the compartments within theparallel belts and any obstructions around the PLZ. The picking unitsthen are translated horizontally away from the PLZ on rails 318 byaction of stepping motor 319. Optionally, the picking units 302 may bedrawn inwardly together by a second actuator 320.

[0048] Thus, as may be seen, the picking units are given athree-dimensional range of motion; up-down in the vertical direction (Zaxis), side to side in the translational direction (Y axis), and theymay be drawn together and spread apart in the horizontal direction (Xaxis).

[0049] It should be noted that, by using a plurality of picking units302, that different packaging runs may go on simultaneously, leading toenhanced flexibility in packaging runs. For example, boxed of 6 piecesof product can be programmed to run in PLZ I, while boxes of 10 piecesof product can be programmed to run in PLZ II. The controller deliversthe right number of pieces of product to each flight, and places it inthe appropriate PLZ as required. Essentially, two runs of product mightbe completed simultaneously.

[0050] The control unit coordinates the activities of the orientationdevice by controlling the belt speeds and duration to control the flowof product, the picking device motion by bringing it over to thesecondary belt in the PLZ, dropping it down vertically to withingrabbing range of the product packing edges, closing the picking fingersupon the product edges, raising the picking device vertically to removethe product from the belt and clear the PLZ, optionally bringing theproduct together, and translating it away from the PLZ to thecartooning, boxing, traying, or wrapping station.

[0051] The controller orients the packages by controlling the speed ofthe first infeed conveyor, where product is originally loaded into theapparatus in what may be a jumbled orientation. The collection ofpackages may be flattened and oriented on the belt by means of guidesand bars, as is known in the art. The controller also controls thesecond infeed conveyor, which has a plurality of vertical dividersthereon defining compartments for the pouches or product to be placed inby the action of gravity or momentum (essentially flinging the productfrom one belt to another).

[0052] The controller controls the speed of the second belt by aid fromthe product detector 112 (FIG. 1). It positions a compartment in thesecond infeed conveyor to “catch” the product and bring it up tovertical orientation where one edge is above the product.

[0053] It is interesting to note that, as the second infeed conveyor isa flexible belt mounted on end rollers, as the belt passes over the endrollers, the angular distance between each vertical divider isincreased, forming an enlarged space therebetween. The target area forpackage delivery is therefore much increased. As the belt passed overthe roller and returns to the upper side, it compresses the compartment,forcing the flexible pouch upward vertically.

[0054] After each flight is loaded into its own group of verticaldividers located on the second infeed conveyor, the controller selectswhich set to drive to which PLZ. The second infeed belt can be dividedinto as many belts as there are needed for flights of product.

[0055] Turning now to FIG. 4, an exemplary single picking device isseen. The opposable fingers 400 are shown coated with an optional outersurface coating of enhanced frictional properties. This coating enhancesproduct grip and reduces dropped product. The frictional enhancingcoating is preferably a resilient polymeric material, to soften the gripof the fingers and lessen the likelihood of product damage. Natural,vulcanized, and synthetic rubber and polymers are suitable for thiscoating. The fingers may be individually dipped into molten rubber,polymer, or mixtures thereof, or the coating may be sprayed on, as isknown in the coating art.

[0056] Optionally, the closing jaws may be formed with ridges 404 toenhance the grip on edge 406.

[0057] Turning now to FIG. 5, the translational motion of the device maybe seen. Picker head 500 is raised in the vertical direction of arrow Aby an effectuator actuator (not shown) to a position above the PLZ 501.The flexible package 503 is seen dangling from two sets of fingers 505.The controller then drives the stepping motor 502 in the direction ofarrow B along rail 504. The picker head(s) are carried over to thecarton loading station 506, which may be another conveyor belt uponwhich is a carton 508. The picker head(s) then descend in the directionof arrow C, the fingers can open, and the flexible package is placed ordropped into the carton.

[0058] Turning attention now to FIG. 6, an especially preferred pickerhead arrangement is seen. Dual picker heads 600A and 600B are mounted onvertical supports 602A and 602B. Vertical supports 602A 602B areconnected to horizontal actuator 604, and are free to move in ahorizontal direction. As the vertical supports 602 A and 602 B descendthrough the action of a vertical actuator (not shown) the horizontalactuator also acts to draw the heads 600A and 600B together, resultingin a motion along the lines of arrows D and E.

[0059] The flexible pouches 606A, 606B, being gripped at a flexible edge608A, 608B by the fingers 610, pivot at the point of connection to thefingers and lie down in an aesthetically pleasing shingled effect.

[0060] In a preferred embedment, there are as seen two heads, whichheads move relative to each other in a horizontal plane in a differentdirection to shingle the product in a different orientation. If thesimultaneously packaged materials are then stacked, a significantsavings of space may be achieved, as may be seen from FIG. 7.

[0061] Thus, to describe the process more fully from beginning to end,goods which are packaged in flexible containers having at least one edgemay now be efficiently packaged in an aesthetically pleasing and rapidmethod by supplying a plurality of goods wrapped in flexible pouches,orienting the goods on a conveyor such that the at least one edge isfacing in an upward direction, and dividing the goods into at least onediscrete group on the conveyor. Then at least one, preferably at leasttwo, picker heads grab the goods in their respective groups whilemaintaining the orientation and grouped relationship of each of said atleast one discrete group of goods.

[0062] The picker heads and thus the grabbed group of goods are raisedfirst upwardly in a vertical direction, then in a horizontal direction,then downwardly into a container for holding a plurality of goods, andthe goods are reoriented in the container into their final arrangement.

[0063] Optionally, the detector which controls the operation of thevarious devices by feeding information to the controller may also be aproduct inspection device. If the product is defective in any way, theproduct may be rejected by simply reversing the receiving belt slightlyand allowing the product to fall to a reject bin where it may beinspected and sent for quality control analysis.

[0064] The inspection may occur preferably during the step of orientingthe product while the apparatus is transferring the goods from the firstconveyor belt to the second conveyor belt located proximate to the endof said first conveyor belt. By running the first conveyor belt at aspeed sufficient to propel the goods to the second conveyor belt; thegoods may be passed by a single inspection camera or a plurality ofinspection cameras for a 360-degree inspection while airborne. Adecision on rejection can be made when receiving the goods. The goodsare caught, or received, on a second conveyor belt having receivingcompartments thereon which hold the goods such that the goods aredisposed with the at least one edge at the top. By reversing thestepping motor, the compartment may be “dumped” over the edge of thebelt.

[0065] While the invention has been described by reference to thepreferred embodiment disclosed herein, the invention is subject toconsiderable modification and may be tailored to fit the needs of manymanufacturing packaging situations without departing from the scope orspirit of the claims which are appended hereto.

1. An apparatus for the placement of a plurality of packaged goods intoa container, wherein the packaged good have at least one edge,comprising: an orientation device which receives the packaged goods andorients them with the at least one edge facing upwardly; a pickingdevice which affixes itself to each of the packaged goods by the oneedge, a translation device connected to the picking device, whichtranslation device has a three dimensional range of mobility, and acontrol unit which coordinates the activities of the orientation device,the picking device, and the translation device.
 2. An apparatus asclaimed in claim 1, wherein the orientation device comprises: a firstinfeed conveyor, and a second infeed conveyor, wherein the second infeedconveyor has a plurality of vertical dividers thereon, whereby theplurality of packaged goods is transferred from the first infeedconveyor to the second infeed conveyor via gravity and momentum, and onepackaged good is placed between two vertical dividers.
 3. An apparatusas claimed in claim 2, wherein the second infeed conveyor comprises aflexible belt mounted on end rollers, and as the belt passes over theend rollers, the angular distance between each vertical divider isincreased, forming an enlarged space therebetween.
 4. An apparatus asclaimed in claim 2, wherein: the second infeed conveyor has a pluralityof groups of vertical dividers; and the second conveyor is divided intoas many separate parallel belts as there are groups of dividers.
 5. Anapparatus as claimed in claim 1, wherein the picking device comprises atleast one picker head unit, and each picker head unit contains aplurality of individual grasping devices.
 6. An apparatus as claimed inclaim 5, wherein each individual grasping device comprises a pair ofopposable fingers which are actuatable to clamp together.
 7. Anapparatus as claimed in claim 1, wherein the packaged goods are aplurality of stand-up pouches, gussetted pouches, Doyen packs, or Doypacks.
 8. An apparatus as claimed in claim 1, wherein the edge isbetween a top and a bottom of the packaged goods.
 9. An apparatus asclaimed in claim 6, wherein the fingers have an outer surface outersurface coating of a resilient polymeric material.
 10. An apparatus asclaimed in claim 5, wherein there are at least two picker head units.11. An apparatus as claimed in claim 10, wherein the picker head unitsare movable relative to each other in at least the horizontal plane. 12.An apparatus as claimed in claim 1, wherein the translation devicecomprises at least one rail upon which the picker head moves relative tothe orientation device.
 13. An apparatus as claimed in claim 12, whereinthe translation device is translated horizontally by a effectuator. 14.An apparatus as claimed in claim 13, wherein the effectuator is astepping motor.
 15. A process for the packaging of goods which arecontained in flexible containers having at least one edge, comprisingthe steps of: supplying a plurality of goods, orienting the goods on aconveyor such that the at least one edge is facing in an upwarddirection, dividing the goods into at least one discrete group on theconveyor, grabbing each of the goods in said at least one discrete groupwhile maintaining the orientation and grouped relationship of each ofsaid at least one discrete group of goods, translating the grabbed groupof goods first upwardly in a vertical direction, then in a horizontaldirection, then downwardly into a container for holding a plurality ofgoods, and reorienting the goods in the container into their finalarrangement.
 16. A process as claimed in claim 15, wherein the step ofsupplying comprises placing the goods on a first conveyor belt and thegoods are a stand-up or gussetted pouch.
 17. A process as claimed inclaim 15, wherein the step of orienting comprises: transferring thegoods from the first conveyor belt to a second conveyor belt locatedproximate to the end of said first conveyor belt by running the firstconveyor belt at a speed sufficient to propel the goods to the secondconveyor belt; and, receiving the goods on a second conveyor belt havingreceiving compartments thereon which hold the goods such that the goodsare disposed with the at least one edge at the top.
 18. A process asclaimed in claim 15, wherein the step of dividing comprises: providing acomposite conveyor belt having a plurality of individual parallel belts,each belt having a plurality of goods compartments arranged in a group,depositing a group of goods onto the composite conveyor belt, one goodper compartment, and individually moving the individual parallel beltcontaining the plurality of goods compartments with the deposited goodstherein.
 19. A process as claimed in claim 15, wherein the step oftranslating comprises: first, elevating the grabbed group of goods in avertical direction sufficient to clear the conveyor; second, translatingthe grabbed group of goods in a horizontal direction in a directionsufficient to transport the grabbed group of goods to a cartoningstation, and third, lowering the grabbed goods into a carton.
 20. Aprocess as claimed in claim 19, wherein, during the step of lowering thegrabbed goods into a carton, the goods and boxes are translatedhorizontally relative to each other, whereby they form a shingledarrangement.